Split-phase motor thermal starting switch



March 25, 1947. H, F- CLARK 2,417,912

.SPLIT-PHASE MOTOR THERMAL'STARTING SWITCH 4 Sheets-Sheet 1 Filed Aug. 31, 1944 \\\\\\\\\X\ I-I ZUR.

March 25, 1947- IH. F. CLARK SPLIT-PHASE MOTOR THERMAL STARTING swTTC Fiied Aug. 51, 1944 4 Sheets-Sheet 2 BIMETAL 228] Immer/u.

BIMITAL N W I s Y B URLO v @mlbvw/ M N March 25, 1947. H F, CLARK SPLIT-PHASE MOTOR THERMAL STARTING SWTTCH FiledTAug. 3l, 1944 4 Sheets-Sheet 3 mMETAL l,

IN VEN TOR.

Patented Mar. 25, 1947 UNITED STATES PATENT OFFICE SPLIT-PHASE MOTOR. THERMAL STARTING SWITCH Harry F. Clark, Oakwood, Ohio, assignor to General Motors Corporation, Dayton, Ohio, a corporation ot Delaware Application August 31, 1944, Serial No. 552,166

metal starting and overload controls for electric motors. One example of such a bimetal starting control is shown in Fig. 2 of the Werner Patent No. 2,117,123. A number of difficulties have prevented the wide use of such a control.

One of the most troublesome factors is the wide range of current values which must be conducted by the starting control. In bimetal starting controls, the motor current is used to first rapidly heat the bimetal operated starting switch until the starting circuit is opened. The motor current must then continue to heat the bimetal operated starting switch to keep the starting circuit open throughout the remainder of the running period of the motor. It is well-known that at the point of use or connection of a device connected to a commercial supply line, the voltage varies widely depending upon the conditions of the system. For example, a nominal 110 volt circuit may deliver current at a voltage of from 90 to 120 or 125 volts.

By testing bimetal starting; controls, it has been found that if sufficient heat is provided for the starting control to give proper starting on a 90 volt current supply, that overheating will occur upon a 120 volt supply. Or if the heating is reduced sufficiently to prevent overheating on 120 volts, the heating will be insucient to cause the bimetal to hold the starting circuit open when the voltage supply drops to 90 volts. Even where the power supply and individual power circuit does not vary to this extent, a manufacturer of starting controls is still confronted with this problem, since the equipment he builds for a nominal 110 volt circuit may be used either upon a power circuit which frequently supplies current at the point of delivery at 90 volts or upon another circuit which may supply current at the point of delivery at 120 or 125 volts. It has, in the past, also been necessary to provide for the manufacture of several different variations of starting` controls to accommodate different current frequencies because the power supply in this country employs in different communities, 25, 50 and 60 cycle current.. It is therefore desirable that one starting control be provided which will operate satisfactorily upon a wide variation of voltages and frequencies.

Another difliculty with bimetal starting and over-load controls is that the operation varies according to changes in the room or environment temperatures. Still another difficulty is that the overload protector may reset before the starting control resets.

It is an object of my invention to provide a practical bimetal starting control for controlling the energization of the phase winding in which the bimetal will not be overheated under any operating condition.

It is another object of my invention to provide a heating arrangement for a bimetal starting control Which will supply suilicient heat to provide proper operation under all expected conditions Without supplying excess heating under any conditions.

Itis another object of my invention to provide a. simple inexpensive starting control in which the timing is kept Within a desirable range regardless of the variations in voltage conditions.

It is another object of my invention to provide a starting control which will operate satisfactorily upon current of 25, 50 and 60 cycles.

It is another object of my invention to provide a starting control in which the timing is kept within a desirable range regardless of changes in the room or environment temperature.

It is another object of my invention to provide means employing a motor starting control for keeping the motor overload protector tripping point within a desirable range regardless of the change in the room or environment temperature.

It is another object of my invention to provide a bimetal starting and overload control in which the overload will reset at the same time or earlier than the starting control.

It is another object of my invention to provide an improved support and arrangement of the ends of a bimetal strip.

It is another object of my invention to provide means for reducing the voltage drop and heating produced within an electro-thermal starting control during the starting period of the motor.

It is another object of my invention to provide an electro-thermal starting control with three different heating rates to properly control the operation during the starting and running periods under al1 conditions without overheating the electro-thermal element..

It is another object of my invention to provide a temperature responsive double 'throw switch mechanism having a snap action effective only during a portion of its movement.

Generally speaking, these objects are attained by providing a starting control in which the bimetal operated switch is heated to a relatively high temperature by current flowing through the bimetal to open the starting circuit and after this opening, the bimetal is short circuited to reduce the heating thereof, after which the short circuit is opened periodically to supply sutiicient heat to the bimetal to keep the starting circuit open during the running period of the motor. The heating of the bimetal produces an amount of heat within the switch casing suiiicient to keep the interior at a substantially constant temperature regardless of any change in the environmenttemperature, so that the tripping time for both the starting and overload controls will not vary materially under different environment conditions. The thermal overload is provided with greater heat storage capacity than the starting control so that the starting control resets before the overload resets.

At least a portion of the bimetal is column loaded to provgide a snap action but the shortcircuiting contact is located outside the range of snap action to facilitate periodic opening and closing of the short-circuiting contact during the running period of the motor. An auxiliary contact opened by the initial movement of the bimetal is optional to reduce the rate of heating of the bimetal and the voltage drop through the starting control during the starting period of the motor. The ends of the bimetal preferably are each provided with a 180 degree edgewise turn and anchored.

Further objects and advantages of the present invention will be apparent from the following description, reference being had to the accompanying drawings, wherein a preferred form of the present invention is clearly shown.

In the drawing:

Fig. 1 is a sectional view taken along the line i--i of Fig. 3 showing one form of motor control .embodying my invention connected diagrammatieally to a diagrammatic split phase motor;

Fig. 2 shows a modified form of heating element to replace one of the heating elements shown in Fig. 1;

Fig. 3 is a sectional View taken along the line 3 3 oi Fig. 1;

Fig. 4 is a sectional view taken along the lines 4-4 of Fig. 1;

Fig. 5 is an enlarged sectional view taken along the line 5-5 of Fig. 1;

Fig. 6 is a diagrammatic view of the starting control and protector connected to a split phase motor with the energized circuits shown in heavy lines and the others shown in thin lines to illustrate the energization of the circuits when the bimetal starting heat is eliminated;

Fig. 7 is a view similar to to Fig. 6 in which the starting bimetal is being instantaneously heated during the running period of the motor;

Fig. 8 is a diagrammatic view generally similar to Figs. 6 and 7 but showing the starting control and overload protector connected to a capacitor start and run type of split phase motor;

Fig. 9 is a diagrammatic view generally similar to Figs. 6 to 8 but showing the starting and overload control connected to a capacitor start motor and provided with a mechanical connection for resetting the starting control when the overload protector trips;

Fig. 1G is a horizontal sectional view taken along the lines iti-I0 of Figs. 11 and 12 showing another form of motor control embodying my invention;

Fig. 11 is a sectional view taken on the line lI-II of Fig.

Fig. 12 is a sectional view taken along the line I2--I2 of Figs. 10 and 11;

Fig. 13 is a fragmentary plan view of a detail of Fig. 10;

Fig. 14 is a wiring diagram of the motor and control system connected for the starting of the motor in which the energized portions are indicated by heavy lines and the deenergized portions by light lines;

Fig. 15 is a wiring diagram similar to Fig. 14 showing the changed connections at the completion of the starting period;

Fig. 16 is a wiring diagram similar to Figs. 14 and 15 showing the other form of connection assumed intermittently during the running period;

Fig. 17 is a wiring diagram showing the control connected to a capacitor start and run motor in starting position;

Fig. 18 is a wiring diagram showing a modied arrangement of the control likewise connected to a capacitor start and run motor in starting position; and

Fig. 1,9 is a temperature-movement diagram of the starting bimetal illustrating the movement of the starting contact with the rise and fall in the temperature of the bimetal.

Referring now more particularly to Figs. 1 to 7, there is shown a split phase electric motor 20 having a main or running winding 22 and a phase or starting winding 24. This electric motor is supplied with electric energy through the supply conductor 26 which connects to the common junction of the windings 22 and 24 and the supply conductor 28 which connects to the starting and overload control, designated generally by the reference character 30.

The overload protector The conductor 28 specifically connects to a. clip 32 mounted upon the switch mounting base 34 made of some suitable insulating material.

This clip supports one end of an electric heater 36, the other end of which is supported by a connector 38 also supported by the base and carrying a stationary Contact 40. .In engagement with the stationary contact 40 is a movable contact 42 carried by the middle of a column loaded bimetal strip 44 which serves as the actuating bimetal of the overload control. This bimetal strip 44 is supported in notches at its left and'right ends which are formed in the arms 46 and 48 o! the main bracket 5U which is riveted to the base 34. The bimetal strip 44 has the material of greater expansibility facing the contact 40 so that upon sufficient heating it will move away from the contact 40. The left end of the bracket 50 is provided with an adjusting screw 52 which may be adjusted to provide any desired column loading upon the bimetal strip 44 by engaging and moving the arm 46 in order to vary the Contact pressure between the contacts 40 and 42 as well as the differential between the opening and closing ot these contacts. This column loading provides a desirable form of snap action of the bimetal strip 44.

The bracket 50 is provided with an ear 54 supporting one end of an electric heater 56 adjacent the right end of the bimetal strip 44. The other end of this electric heater 56 is supported by the right starting relay bracket 58. The heater 58 is located adjacent the bimetal 44 so that upon energization of the heater it will quickly apply its heat to the bimetal 44.

The heater 62 When it is more desirable to apply additional heat to the starting bimetal strip 68', the electric heater 62, in the angular position shown in Fig. 2, may be connected toy the ear 54 and the lower starting relay bracket 58 in a manner similar to the heater 56. However, if desired, both heaters may be used simultaneously so as to provide adciitional heat for both the bimetal strips 44 and The starting central The starting bimetal strip 60 is supported at its right end in a notch in the lower starting relay bracket 58 and its left end in a notch in the arm 64 of the lett starting relay bracket 6 6. The arm 64 may be adjusted by the set-screw 68 which engages it to vary the column loading upon the bimetal strip 68. The column loading of the bimetal strip provides a desirable form of snap action, the differential of which is varied by the adjustment of the set-screw 68. At its mid-point the bimetal strip 68 carries a double ended contact 1 n extending upon oppOSlte sides of the strip 60. This contact also serves to fasten a pigtail clip 12 to the strip 68. The main bracket 58 is provided with an up-turned ear 14 carrying a stationary contact 16, called a. back contact, which may be engaged by one of the movable contacts 10 when the bimetal 60 is heated suiliciently. The other end of the double ended movable contact 10 is adapted to contact the stationary contact 18 upon the starting connector 88 which is fastened to the base 34 and connected by the conductor 82 to the opposite end of the phase winding 24.

The stationary contact 18 is placed l slightly closer to the dead center line of the strip 60 than the back contact 16, so as to get greater contact pressure when the strip 60 is cold and to obtain a better snap action upon the separation of the contacts 18 and 18. The placing of the back contact 16 slightly further away from the dead center line of the strip 68 allows the strip 60 to creep away without snapping over center after being heated and after the contact 18 contacts the contact 16. The material of greater expansibility in the bimetal strip 60 faces the contact 18.causing the strip to move toward the back contact 16 when heated. At room temperature the bimetal strip 60 is bowed when unstressed in the same direction but in a slightly greater amount as in Fig. 1.

The clip 12 supports one end of a ilexible electric cable or pig-tail connection 84, the other end of which is connected to the pig-tail supporting clip 86, fastened to the base 34 and connected by the conductor 88 to the other end of the main winding 22. All the elements shown mounted upon the switch mounting base 34 in Fig. 1 are covered by the cover 98, also oi insulating material, which slips over the base, as is better Ashown in Figs. 3 and 4, and is held in place by the bosses or projections 92 formed upon the inside of the side walls of the cover. The cover 98 has suillcient ilexibility to allow the insulating base to be pressed into position where it rests between the shoulders 94 and 96 at the corners o! the cover and the shoulders on the projections 92 upon the sides of the cover.

Operation In operation, when the motor 28 is idle and the motor control is at ordinary room temperatures, the bimetals 44 and 60 will assume the position shown in Fig. 1. Under such circumstances electric energy will flow through the conductor 28 to the clip 32, thence through the overload heater 36 to the overload connector 38, through the contacts 40 and 42` and from the contact 42 the current will ilow in both directions through the bimetal strip 44 to the arms 46 and 48 of the bracket 58. The current will then ilow through the bracket 50 from the arms 46 and 48 to the ear 54, thence through the heater 56 to the right bracket 58 of the starting relay and thence up through the right half of the starting bimetal strip 60 to the contact 10 which is in engagement with the contact 18 from which some of the current ows through the conductor 82 and thence through the phase winding 24 to the other supply conductor 26. In addition, current will flow rfrom the clip 12 through the pig-tail 84 to the pig-tail clip 86 which is connected by the conductor 88 to the main or running winding 22 which is joined to the other supply conductor 26.

The starting bimetal strip 68 has its width reduced to about one-half or one-third the Width of the strip 44 so that it will be heated much more rapidly and to a higher temperature by this current ilow than the bimetal strip 44. Also, all the current flows through one end of the strip 60 While the current divides in the strip 44 so that one-half of the current flows through each half of the strip 44. Through these measures, the heating effect in the strip 44 is reduced to such a value that it will not trip on a normal starting or running current despite the fact that it is supplied with additional heat by the heaters 36 and 56.

In order to obtain the most powerful starting of a split phase motor it is desirable that the starting winding remain connected until the torque produced by both windings attains its maximum value and becomes less than the torque produced by the running Winding alone. It is preferable that the deenergization of the starting winding take place after this speed is reached and before balancing speed is reached. In this control, this is accomplished by selecting the proper width and thickness of the bimetal strip 60, by adjusting the column loading of the bimetal strip 60 through the adjusting screw 68 which bears upon the arm '64, and by properly locating the contacts 16 and 18 relative to the contact 10 so that when this speed range is reached, enough current has flowed through the bottom half of the bimetal strip 60 to heat it suilciently to snap to the oDpOsite side of its dead center line to cause the contacts 10 and 18 to separate between the speed at which the highest torque is obtained and the balancing speed.

After thus snapping, the bimetal strip 60 is in the position shown in Fig. 6 wherein the contact 10 engages the contact 16 so as to close a shunt through the bracket 50 which stops the current I iiow through the bimetal strip 60 and the heater 56 or 62 or both. In this connection, as shown by the current ilow in heavy lines in Fig. 6, the current flows through the conductor 28, thence through the overload heater 36 and through the contacts 40 and 42 and thence in opposite directions through the bimetal strip 44 to the main bracket 50 through which it ilows directly to the stationary contact 16 and the starting Contact 10, thence through the pig-tail 84, the conductor 88, thence through the main winding 22 to the other supply conductor 26. During -this time both the bimetal 60 and the heater 56 will cool.

The snap action characteristics of the bimetal 60 and the location of the contact 16 are such that it may creep away from the contact 16 when it is cooled a limited amountl without snapping back` so that the starting contact 18 will not immediately reclose with the starting contact 18. As a result, when thel bimetal '68 cools, it will creep and assume the position and energize the heavy line circuits shown in Fig. '1. In this condition, neither the Contact 18 nor the contact 16 is contacted by the movable starting contact 18. Under these circumstances, current will ilow through the supply conductor 28, the overload heater 36,

the stationary overload contact 48, the movable overload contact 42 and through the bimetal strip n4 in'opposite directions, thence through the main bracket 58 to the heater 56, thence through the heater 56 and the right portion of the bimetal 68 as well as the pig-tail 84, the conductor 88 and the main Winding 22 to the supply conductor 26. No current will loiv through the phase winding 24 because of the separation of the contacts 18 and y523. rThe iiow of current through the heater 56 and the bimetal 68 set up by the separation of the contacts 18 and 16 raises the temperature othe bimetal 68 and causes it to again contact the back Contact 16 to again restore the circuit shown in Fig. 6.

The restoration of the circuit shown in Fig. 6 will cause the bimetal strip 60 to creep away from the back contact 16 to restore the circuit shown in Fig. 7. The control will then alternate between the circuits shown in Figs. 6 and 1 to supply just enough heat to the bimetal 60 to keep it from returning to the position shown in Fig. 1. While it may at rst be considered that this alternation from the circuit shown in Fig. 6 to that shown in Fig. 7 and vice versa would be highly objectionable, this is not true since at all times the voltage difference between the contacts 10 and "i6 is very small, because of the small resistance of the bimetal strip 68 and the electric heater' 56 which these contacts shunt out.

There is a further advantage in this arrangement. The bimetal strip 60 and the electric heater 56 give oi 'neat to the interior of the cover S. t is obvious that when the room temperature is low more heating will be required to keep the bimetal strip 68 in its running positions shown in Figs. 6 and '1, and hence the circuit will be arranged as shown in Fig. 7 a proportionately greater part of the time, Whereas when the room is Warm there will be an increase in the proportion of the time that the circuit is arranged as shown in Fig. 6 wherein no heat is given oi by the strip 68 and the heater 56. This heating therefore is substantially in inverse proportion to the room or environment temperature and very nearly compensates for changes in the room or environment temperature so that the temperature within the casing 98 is substantially the same during all periods of operation and this substantially compensates the thermal overload protector and particularly the bimetal strip 44 for changes in environment temperature so that it will trip at substantially the same maximum current value regardless of the changes in room temperature. This effect is slightly increased when the heater 56 is used so that the heat is applicn more directly to the strip 44. It so happens, however, that with some motors operating upon abnormally low supply voltages the current ilowing through the bimetal strip 68 iS insufilcient to hold the strip 68 in the position shown in Fig. 7. Under such circumstances the heater 8 62 may be used either with or without the heater 58, to add to the heating eiiect flowing through the bimetal strip 88 to hold it in the Ditlonl showninFigs.7and6duringtherunningpex-iod of the motor.

While the control is shown applied to its most common application. namely the inexpensive split phase motor, it may also be used with the more expensive types oi split phase motors such as the capacitor start type ofsplit phase motor diagrammatically shown in Fig. 9, and the capacitor start and run motor diagrammatically shown in Fig.8. InFig.8itwillbeseenthatthestart ing control is unchanged and includes the overload heater 38 connected to the stationary overload contact 48 which is engaged by the contact 42 carried by the overload bimetal strip 44. This bimetal strip 44 is connected by the bracket 88 to the heater 56 and the back contact 18. The heater 56 is connected to the bimetal 88 which carries the starting contact 18 shown in engagement with the stationary starting contact 18. The movable starting contact 18 is connected by the pig-tail 84 and the conductor 88 to the main winding |22 of the capacitor start and run motor |28. The motor |28, however, is provided with a phase winding |24 which is connected by the conductor |82 to the starting capacitor |88 which in turn is connected by the conductor |88 to the starting contact 18. The conductor |82 is also connected to the running capacitor |8| which is also connected to the conductor 88 so that;l it is connected at all times between the phase winding |24 and the main winding |22.

With this motor, current is supplied through the supply conductor |28 to the overload heater 36, the overload bimetal strip 44, the heater 88 and the starting bimetal 68 in a manner Just as described for Fig. 1. Current also ows through the pig-tail 84 and the conductor 88 to the main winding |22 and also to the running capacitor.

v the conductor |85, the starting capacitor |88 and the conductor |82 to the phase winding |24. This provides the necessary current for the motor |28 to start.

When sulcient current ows through the starting bimetal strip 68, it will trip to place the movable contact 18 in engagement with contact 16 thus shunting the bimetal strip 68 and the heater 56. During the remainder of the running period of the motor. no current will ilow through the conductor |85 and the starting capacitor |88 but current will continue to ow through the conductor 88 and through the main winding |22 to the supply conductor |26 and also through the running capacitor |8| and the conductor |82 and the phase winding |24 to the conductor |28. The bimetal 68 will creep away from time to time to separate the contacts 18 and 18 to allow sumcient current to ow through the heater 58 and the bimetal strip 68 to keep the strip 88 upon the rightside of its dead center position so that the contact 18 will not re-engage the contact 18 during the remainder oi the operation of the motor.

It should be noted that in all the arrangements, overheating of the bimetal strip 88 is prevented since, when sufhcient heat to the bimetal strip 68 is supplied to trip it across its dead center po sition so as to separate the contacts 18 and 18,

the back contact 16 is engaged to remove all the heating eii'ect from the bimetal strip 68. In this way previous objections to the bimetal type starting control have been overcome. Sufficient heating effect can always be applied to the bimetal strip 68 to cause it to move from the left to the right side of its dead center position to separate thecontact 18 from the Contact 18 and to keep them separated throughout the running period of the motor without the danger of applying so much heat that the bimetal 68 will become overheated and lose its temper and get out of calibration.

Fig. 9

This is also true Where my starting control is applied to a capacitor start motor 228 such as is shown in Fig. 9 having a main winding 222 and a phase winding 224 which is connected by the conductor 282 to a starting capacitor 283 which in turn is connected by the conductor 285 to the stationary starting contact 18. The main winding 222 is connected at one end to the common junction connecting to the supply condu^tor 226 while the other end is connected by the conductor 88 to the pig-tail 84 just like. the connections shown in Figs. l to 7. The other supply conductor* 228 is connected Ato the .overload heater 36 which is connected to the stationary contact 48 con, tacted by the movable Contact 42 of the overload bimetal strip 44 which is connected by the bracket 58 to the back contact 16 and the heater 56 which connects to the starting bimetal strip 68 provided with the movable starting contact 18.

Thus, the capacitor start motor may be controlled by the same control shown specically in Figs. lato and illustrated diagrammatically in The overload protector The conductor 128 specically connects to an L-shaped mounting bracket 132 having its lower -portion beneath the switch mounting base 134. This'lower portion is riveted to the base 134 by a hollow rivet'which is threaded toreceive the fastening s^rew 13| which fastens the supply conductor 128 to the bottom of this L-shaped 'mounting bracket 132. The upper portion oi.' the L-shaped mounting bracket 132 extends upwardly through a slot in the switch mounting base 134 and to it is fastened by welding or soldering one Figs. 6 to 8. In all of these controls, the overload bimetal strip 44 is provided with a sufficient heat storage capacity and a suiiiciently large differential so that when it trips open it will remain open at least a suiflcient length of time to allow the starting bimetal strip 68 to cool and return to the starting position shown in Fig. 1. If it is not desired to rely upon this arrangement, a simple mechanical means may be used to positively throw the starting bimetal strip 68 back to its starting position shown in Fig. 1 when the overload bimetal strip` 44 moves to the open circuit position. In Fig. 9 such a connection is shown. In this figure, a rod 358 of insulating material is slidably mounted ina pair of. ears. The rod 358 is just long enough so that when the overload bimetal strip 44 snaps afross its dead center position to the dot and dash lineposition shown in Fig. 9 the other end will engage the bimetal 68 to move it across its dead center position to the dot and dash line position where the movable startingcontact 18 will engage the stationary contact 18. The rod 358 will continue to hold the starting bimetal strip 68 in this position until the overload bimetal 44 resets.` During this time, the starting bimetal strip 6 will cool and the snap. action characteristics of the starting bimetal strip 68 can be depended upon to retain the starting bimetal strip 68 in this position for the starting of the motor which will follow instantly upon the reclosing ofY the overload protector. y;

SscoNn Foxx supplied with electric energy through the supply conductor 126 which connects to the common` end of a coiled electric heater 136. The other end of the electric heater is supported by an L-shaped stationary contact 148 which extends through the base 134 and is riveted thereto. yIn engagement with the stationary contact 148 is a movable contact 142 carried by the middle of a column loaded bimetal strip 144 which serves as the actuating bimetal of the overload control. The stationary contact 148 is so located that when engaged by the movable contact 142. the bimetal strip will be held substantially straight.

In Figs. 1 to 9 the bimetal strips are shown supported on knife edges with the current owing from the ends of the strip to the supporting knife edges. This arrangement may, under some circumstances, cause corrosion at the ends of the bimetal, which would affect operation of the control. To avoid this possibility, the ends of the bimetal strip in this second form, are welded to the ends of themain bracket 158. However. if the ends of the bimetal strip were connected directly to this main bracket 158 without a bend or merely `by simple bends, the effect of temperature upon these ends would be opposite to the bowing of the midpoint of the bimetal strip 144 under an increasing temperature. That is, when the bimetal 144 would tend tobow to the right at its midportion the plain anchored ends of the strip would tend to bend clockwise at the top and counter-clockwise at the bottom so as to force the midpoint of the bimetal strip 144 to'the left. In

order to prevent this opposition and to make both effects supplement each other, I provide edgewise bends 143 and 145 through an angle of 180 degrees at eachend of the strip 144 and I'pend each of these turned portions at right angles vand weld their ends 141 and.148 to projections formed on 'theup-turned ends 146 and 148 of the main bracket .158. This causes the bimetal ends to accentuate lthe bowing of the midportion oi the strip 144 by bending counter-clockwise at the top'and clockwise at the bottom, and this makes it possible to make the control smaller.

The up-turned end 148 is provided with an adjusting` screw 152 which may be adjusted to provide any desired column loading upon thebimetal strip 144 by engaging the welded right angled portion 149 of the strip 144. In this column loading, the right angled portion 149 acts as a compound cantilever spring for applying the column loading in direct alignment with the strip 144 when in the closed position. This column loading insures a snap opening and closing of these contacts which can be separately adjusted. The adjustment provided by the screw 152 varies the force required to close the overload contacts 142 and 140. This force is obtained by the cooling of the bimetal and thus the adjusting screw 152 may be set to vary the closing temperature of the overload contacts. The opening of the contacts is adjusted by moving the stationary contact 148 toward or away from the strip 144. Moving the contact 148 toward the strip 144 will reduce the contact opening temperature while moving the contact 148 away from the strip 144 will increase the contact opening temperature. The Width, thickness and length of the bimetal strip 144 and the resistance of the auxiliary heater 138 may ne varied to provide the proper overload characteristics for diierent motors.

The starting control The bracket 158 is riveted to the switch mounting base 134 and provided with a longitudinal stiffening rib. The turned up end 148 supports the lower end of the starting bimetal strip 168 which like the overload bimetal strip 144 has its end' portions turned edgewise 180 degrees and then at right angles for similar reasons. The end of the lower right angled portion 158 is welded to the turned up portion 148 and is provided with a set-screw 168 for applying a resilient column loading to the strip 168 in which the right angled portion 159 acts as a compound cantilever spring which applies the column loading in substantially direct alignment with the strip 188 when in contact with the starting contact 118. At the upper end oi' the strip 168 the right angled end portion is weldedto a projection on the turned up portion of a separate bracket 166 likewise riveted to the switch mounting base 134. At its midpoint the starting birnetal strip 168 carries a doubleended contact 118 which when the strip 168 is cool engages with considerable contact pressure, the starting contact member 118 which is in the form of an L-shaned bracket extending beneath the switch mounting base 134 and is riveted thereto. The starting contact member 118 is so located that when it is engaged bv the doubleended contact 118; the starting bimetal strip 188 is held substantially straight. This starting contact bracket is provided with a binding screw 119 which connects to the conductor 182 connecting the contact 118 with the phase winding circuit.

The auxiliary heater and contact mechanism Connected to the bracket1i6 is one end of an electric heater 156 which extends alongside the starting bimetal strip 168 and has its other end fastened to the L-shaped back contact member 114 which extends through the switch mounting base 134 and is riveted thereto. On its bottom face it is provided with a binding screw 115 which connects this back contact member with the conductor 188 of the main winding circuit.

The bracket 168 is also shown provided with an auxiliary contact member 184 in the form of a cantilever spring provided with an auxiliary contact 185 riegagement with the back of the back contact 114. The end of this auxiliary contact member 184 is curled and covered with insulation 188 which places it just out of contact with the bimetal strip 168. The switch mounting base 184 is preferably of some suitable electrical insulating material and is preferably mounted within a casing 188 likewise of insulatingmaterial and held in place against the shoulders 194 provided in the corners by the projections 192 provided upon the sides of the case.

lCurrent flow in the second form With this arrangement when the motor 128 is first connected to the power line, as illustrated by the heavy lines in Fig. 14, current will flow from the supply conductor 128 to the bracket 132, thence through the heater 136 alongside the overload bimetal strip 144 to the stationary contact 148 and the movable Contact 142. From this point the current will divide and ilow in opposite directions throughout the overload birnetai strip 144 until it reaches the points at which it is welded to the projections extending from the upturned ends 146 and 148 of the main bracket 158. The characteristics of the heater 136 and the characteristics and adjustment of the bimetal strip 144 will determine the current values which will cause the overload bimetal 144 to trip open to deenerglze the motor upon an overload. The column load imposed by the set-screw 152 will determine the temperature to which the overload bimetal strip 144 will fall and thus the resetting time before it will snap to its closed position. This resetting time. must be made longer than the resetting time of the starting bimetal strip 168. By arranging the contacts so that the overload bimetal strip 144 is held straight when closed, the tripping current and the resetting time and temperature can be separately adjusted.

From the ends of the overload bimetal strip 144, the current will fiow through the main bracket to the point at which right angled portion 158 of the starting bimetal 168 is welded to the weld projection provided on the up-turned end 148. All this current will then pass upwardly through the lower portion of the starting bimetal strip to the double contact 118 at its midpoint. There more than half the current will ow through the contacts 118 and 118 to the starting winding circuit including the conductor 182. the capacitor and the starting winding 124 t0 the supply conductor 128. The remainder oi' the current will flow through the upper portion oi.' the starting bimetal strip 188 to the bracket 168 and thence through the auxiliary contact member 184 and its contact 185 to the back contact 114 which connects to the main windingr circuit including the conductor 188 and the main winding 122 which connects to the supply conductor 118.

Operation ol the second form Upon the initial starting of the motor. the bimetals 144 and 188 will be at room temperature and the control will be in the positions shown in Figs. 10 to 12 and 14. This is indicated by the point 828 upon the diagram shown in Fig. 19. Although it is held substantially straight by the starting contact 118. at room temperature the starting bimetal strip 188 tends to bow to the left so as to press tightly against the starting contact 118 with a pressure of more than 3 oz. The now of current through this starting bimetal strip will gradually raise its temperature as illustrated by the vertical line extending up from the point 828 to cause it to rapidly reduce its tendency to bow to the left. The starting bimetal strip 188 is of `auch thickness. width and initial curvature that at the most desirable time for terminating the starting period it will become straight. When the temperature gets so high that the pressure against the starting contact 13 11| reaches zero, the starting bimetal strip 188 will snap and bow to the right tothe position shown in Fig. 15. This snapping or tripping .temperature is indicated by reference character |22 in Fig. 19, and the movement of the contacts 118 at this temperature is designated by the horizontal line connecting point 822 and the point 824. This snapping or tripping temperature may be raised or lowered by bending the starting contact 118 away or toward the starting bimetal strip 160, thus increasing or reducing the length of the starting period. By arranging the starting contact 118 so that the strip 160 is held su stantially straight during the starting period, here is substantially no resistance to leaving the starting contact 118, and less heating of the bimetal strip 168 is required and a heavier bimetal material may be used. It also reduces the energy consumed by the starting control f during the starting period as well as during the running period, thus increasing the net amount available for the motor.

At an intermediatepoint, 825, in this movement the insulated und 186 of the auxiliary contact member 184 is contacted by the adjacent portion of the bimetal strip 168 to carry'the auxiliary contact member 184 with it to move the auxiliary contact 185 away from the back contact 114 as shown in Figs. 13 and 15. This point 825 should be well within the snap action range of the strip 160 and may be set by varying the bend or curl at the insulated end of the `auxiliary conta-ct member 160. Prior to this time, that is, between the points 820 and 822 in Fig. 19, the auxiliary contact member 184 has had its contact 185 in contact with the rear face o! the back contact 114, thereby shunting the external heater 156 and as a result the action of the bimetal strip 188 has been due entirely to the current flowing through it. After the point 825 is passed the auxiliary contact member 185 remains open and instead of cwing from the bracket 186 through the auxiliary contact member 184, the main winding current ilows from the bracket 166 through the heater 156 to the back contact 114.

This heating, however, is only momentary and of no importance at this time, since the bimetal is travelling rapidly under the force of the snap action column loading and reaches the back contact 114 without a pause. The column loading of the bimetal strip 16|) is such that at the tripping temperature indicated by the horizontal line 822 to 824, the contact 110 will just be in contact with the back contact 114 without any contact pressure. In action. however, due to inertia the contact 118 will strike the back contact 114 with considerable force. This immediately shunts both the heater 156 and the upper half of the starting bimetal 160. The main winding current flowing through the lower half of the starting bimetal 160 to the back contact 114 is insutllcient to prevent the bimetal 160 from cooling slowly but it is suilicient to prevent rapid cooling. This causes the bimetal 180 to gradually creep away from the back contact 114 to the position illusi trated in Fig. 16.

Inl creeping away from the back contact 114, the movement is opposed by the gradually increasing resistance due to the column loading of the bimetal strip 160. This movement, however, is beyond the snap action range and is represented by the curve between the points 824'and 826 in Fig. 19, which shows that as the temperature falls, the movement becomes less due to this increasing resistance. However, as soon as the 14y bimetal contact 118 leaves the back contact 114 the shunt for the heater 158 and the upper portion of the bimetal strip 180 is opened and current again ilows through the upper portion of the strip 180 and the heater 158. 'I'his heat is suilicient to slow down themovement of the strip 160 and to stop it .and reverse its movement so that it place repeatedly during the normal running period of the motor. In Fig. 19 this'is represented by repeated movements from the point 824 downwardly a variable distance along the line toward the point 826. It is through this cycling on the back contact that the temperature of the bimetal is kept substantially constant during the normal running period and is prevented from overheating. The resetting time of the starting bimetal strip 180 is regulated by this cycling temperature. This cycling temperature may be raised or lowered by bending the back contact 114 away or toward the strip 160 or by increasing or reducing the column loading by adjusting the setscrew 168 or both. It also is provided through this means with suilicient heat to prevent it from snapping back to the starting position. This cycling on the back contact takes place outside of the snap action range provided by the column loading of the strip 160. During all of this cycling the auxiliary contact 185 is held away from the back contact 114 because the bimetal strip 180 is beyond the snap action range and beyond the zone at which the auxiliary contacts are permitted to close. The cycling on the back contact provides thermostatically controlled heating of the interior of the case 190 so as to reduce the variations in the temperature therein due to changes in room temperature.

When the motor circuit is opened to shut off the motor, the bimetals and heaters will cool. In cooling, the bimetal 160 will reach the point of maximum resistance of the snap-acting column loading applied to it immediately after it passes in cooling below the point 826 in Fig. 19. It will cool without much movement until it cools to the point designated by the reference character 828 where it enters the snap action zone or range of movement. Upon passing this point, without any appreciable cooling, the bimetal strip 180 will snap immediately into contact with the starting contact 118. This movement is designated by the horizontal line extending from the point 828 to the point 838 located on the vertical line between the points 828 and 822. As the bimetal strip 160 snaps toits initial position, as illustrated by Fig. 14, the point 832 in Fig. 19 will be crossed. This is the point at which the auxiliary contact again makes contact with the back contact 114 and it is also the point at which the bimetal strip 160 becomes separated from the insulated end 186 of theauxiliary contact arm 184.

Should there be an excessive current ow vthroughfthe circuit the starting bimetal strip 168-- will cycle normally on the backcontact thereby limiting its temperature until the thermal overload bimetal strip 149 is heated to its tripping move in one direction beyond the snap action l0 range, and means for slowly vibrating said thermally operated device within a limited range beyond the snap action range including means for intermittently momentarily reducing the heating of said thermally operated device to an amount suiilcient to cause it to move in the opposite direction when it reaches the limit of said limited range, said reduced amount of heating being sumcient to prevent the thermally operated device from returning the contact device to contact with the stationary contact before sufficient heating at the higher heating rate again reverses its direction of movement.

5. A control adapted to change the circuit connections of the phase winding of an electric motor having main and phase windings, a snap acting thermally operated device. operable between two extreme positions on opposite sides of a snapping position to operate said control device and normally biased to one of its extreme positions wherein it closes the control device, means responsive to the initial ow of current through the motor for heating the thermally operated device for causing after a predetermined lapse of time the thermally operated device to snap from said one extreme position through its snapping range and to move beyond said range, and means for slowly vibrating said thermally operated device between said snapping range and its other extreme position including means for intermittently momen- 4o tarily reducing sulciently the heating of said thermally operated device when it reaches said other extreme position to cause it to move in the opposite direction.

6. A control for controlling the circuit connections of the phase winding of an electric motor/ having main and phase windings comprising a column loaded bimetal strip portion having a snap acting range and adapted to move in one direction when heated and in the opposite direction when cooled., a normally stationary contact connected to said phase winding located in that portion of the snap action range to which the strip portion moves when cool for closing the circuit between it and a portion ofthe bimetal, a second normally l*stationary contact connected to said main winding located beyond that portion of the snap ac-A tion range to which the bimetal strip portion mov when heated for closing the circuit between it and said bimetal strip portion, two separate points of said strip portion being connected to the main winding and one side of the power supply.

'Ii A control for controlling the circuit connections of the phase 'winding of an electric motor having main and phase windings comprising a column loaded bimetal strip portion having a snap acting range and adapted to move in one direction when-heated and in the opposite direction when cooled, a normally stationary contact connected to said phase wlnding'located in that portion of the snap action range to which the strip portion moves when cool for closing the circuit be tween` it and a portion of the bimetal, means for heating said strip portion ln accordance with the current owing through the motor and for sup-- 18 plying current to said strip, and means including a second normally stationary contact located beyond that portion of the snap action range to of movement, contact means carried by said strip portion, a rst normally stationary contact located to stop said contact means at a position to stop said strip portion within said snap acting range upon cooling, a second normally stationary contact located upon the opposite side of said strip portion to stop said contact means at a position to stop said strip portion beyond said snap action range upon heating, an electric heater extending along said strip between said second contact and an end portion of said strip portion, an electric motor having main and phase windings, said second contact being provided with a connection, said strip portion being provided with a i connection spaced from said end portion, one of said connections being connected to the main winding, and the other being connected to one side of the single phase supply source, said first contact being provided with a connection with the phasewinding.

9. Iny combination, a column loaded bimetal strip portion having a limited snap action range of movement, contact means carried by said strip portion, a 'rst normally stationary contact located tostop said contact means at a position to stop said strip portion within said snap acting range upon cooling, a second normally stationary contact located upon the opposite side of said Strip portion to stop said contact means at a position to stop said strip portion beyond said snap action range upon heating, an electric heater extending along said strip between said second contact and an end portion of said strip portion, an electric motor having main and phase windings, said second contact being provided with a connection, said strip portion being provided with a connection spaced from said end portion, one of said connections being connected 'to the main winding and the other being connected to one side of the single phase supply source, said first contact being Fprovided with a connection with the phase winding, and means for shunting said electric heater when said conta :t means is in contact with said first contact and for opening the shunt whenever the contact means is separated a predetermined distance from said rst contact.

10. A control for controlling the circuit connections of the phase winding of an electric motor having main and phase windings comprising a bimetal strip portion adapted to move in a first direction when cooling and in a second direction f when heating, a normally stationary contact connected to said phase Winding so positioned as to stop the movement of said strip portion in said rst direction when said strip portion is substantially straight, means for applying a column loadcolumn loading, means for heating said strip portion in accordance with the current owing through the motor and for supplying current to said strip, and means including ya second normally stationary contact so positioned as to stop 19 the movement of said strip portion in said second direction when said strip portion is curved a predetermined amount for reducing said heating suiiiciently to prevent the overheating of said strip.

11. In combination with an electric motor having main and phase windings with one end of each connected to one side of a power source, a control device including a Stationary contact connected to the phase winding, a column loaded snap acting bimetal strip portion having a movable intermediate portion between the points of application of the column loading carrying a contact movable with it, said movable intermediate portion being adapted when cool to move said movable Contact into engagement with said stationary contact, a second stationary contact so located upon the opposite side of the bimetal strip portion from said iirst stationary contact that it is contacted by the movable contact when the column loaded strip portion is heated and bows to a predetermined degree, conductor means connecting one end portion of the column loaded strip portion to the other end of the main winding and the other end portion of the strip portion to the other side of the power source, and electrical heating means electrically, connecting the second stationary contact to one of the end portions of said column loaded strip portion for heating said strip portion.

12. In combination with an electric motor having main and phase windings with one end of each connected to one side of a power source, a control device including a stationary contact connected to the phase winding, a column loaded snap acting bimetal strip portion having a movable intermediate portion between the points of application of the column loading carrying a contact movable with it, said movable intermediate portion being adapted when cool to move said movable contact into engagement with said stationary contact, a second stationary contact so located upon the opposite side o! the bimetal strip portion from said' rst stationary contact that it is contacted by the movable contact when the column loaded strip portion is heated and bows to a predetermined degree, conductor means connecting one end portion of the column loaded strip portion to the other end of the main winding and the other end portion of the strip portion to the other side of the power source, and conductor means electrically connecting the second stationary contact to said other end of the main winding.

13. In combination with an electric motor having main and phase windings with one end of each connected to one side of a power source, a control device including a stationary Contact connected to the phase winding, a column loaded snap acting bimetal strip portion having a movable intermediate portion between the points of application of the column loading carrying a contact movable with it, said movable intermediate portion being adapted when cool to move said movable contact into engagement with said stationary contact, a second stationary contact so located upon the opposite side o1' the bimetal strip portion from said rst stationary contact that it is contacted by the movable contact when the column loaded strip portion is heated and bows to a predetermined degree, conductor means connecting one point upon the column loaded strip portion to the other end of the main winding and another point upon the strip portion to the other side of the power source, and conductor means electrically connecting the second stationary contact to one of said points.

HARRY F. CLARK.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,830.578 Vaughan Nov, 3, 1931 2,133,309 Schmidinger Oct. 18, 1938 2,177,671 Schmidinger Oct. 31, 1939 2,095,579 Werner Oct. 12, 1937 2,132,888 Werner Oct. 11, 1938 2,158,288 Kuhn May 1 8, 1939 2,175,032 Schaefer Oct. 3, 1939 

